1998 HONDA CR-V joint

Front Suspension
Knuckle/Hub Replacement (cont'd)
20. Remove the cotter pin from the lower arm ball joint
castle nut, and remove the nut.
COTTER PINReplace.On ra6ssembly,bend the cofter pin
CASTI.E NUT12 x 1.25 mmilg - 59 N.m (5.0 - 6.0 kgf.m, 36 - a3 lbf.ftl
CASTLE NUT12 x 1.25 mm
COITER PINReplace.
BALL JOINT REMOVER, 28 mm07MAC - Sl(xr2(x,
Install a 12 mm hex nut on the ball joint. Make sure
the hex nut is flush with the ball joint pin end, or the
threaded section of the ball joint pin might be dam-
aged by the ball joint remover.
Use the special tool as shown on page 18-11 to sep-
arate the ball joint and lower arm. lf necessary,
apply penetrating type lubricant to loosen the balljoint.
18-12
23. Remove the cotter pin from the upper ball joint cas-
tle nut, and remove the nut.
COTTER PINReplace.On reassembly, bendthe cotter pin as shown.
CASTLE NUT10 x 1.25 mm39 - 47 N.m14.0 - ,4.8 kgt m,29 - 35 tbt.ftl
24.
25.
26.
10 mmnEMOVER, 28 mm07MAC _ SLtD2(xl
Install the 10 mm hex nut on the ball joint.
Make sure the hex nut is flush with the ball joint pin
end, or the threaded section of the ball joint pin
might be damaged by the ball joint remover.
Use the special tool as shown on page 18-11 to sep-
arate the ball joint and knuckle. lf necessary, apply
penetrating type lubricant to loosen the ball joint.
Pull the knuckle outward, and remove the driveshaft
outboard joint from the knuckle by tapping the driv+
shaft end with a pl8stic hammer, then remove the
knuckle.
KNUCKI.ECheck lor damage.
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Front Suspension
31.
Knuckle/Hub Replacement (cont'dl
Wash the knuckle and hub thoroughly in high flash
point solvent before reassembly,
Press a new wheel bearing into the knuckle using
the old b6aring, a plate. the special tool, and a
press. Place the wheel bearing on the knuckle with
the pack seal side facing (metal color) toward the
inside. Be careful not to damage the sleeve of the
Dack seal.
DOUBLE LIP SEALIBLACK COLORI
SUPPORT BASE0?965 - SD90t00
33. Install the circlip securely in the knuckle groove.
35. lnstall the hub on the knuckle using the specialtools
shown and a hydraulic press. Be careful not to dis-
tort the splash guard.
ORIVER077irg - 0010000
SPLASH GUARO
lnstall the knuckle in the reverse order of removal,
and pay particular attention to the following items:
. Be careful not to damage the ball joint boots
when installing the knuckle.
r Torque a\ mount
g hardv{are to ths speci{ied
torque values,
o Torque the castle nuts to the lower torque speci
fications, then tighten them only iat enough to
align the slots with each pin hole. Do not align
the castle nut by loosening.
a lnstall new cotter pins on the castle nuts or hex
nut after torquing.
. Avoid twisting the sensor wires when installing
the wheel sensor.
. Before installing the brake disc, clean the mating
surfaces of the front hub and the inside of the
brake disc.
. Before installing the spindle nut, apply a small
amount of engine oil to the seating surface oJ the
nut. After tightening, use a drift to stake the spin-
dle nut shoulder against the driveshaft.
. Before installing the wheel. clean the mating sur-
face of the brake disc and the inside of the wheel.
. Check the front wheel alignment, and adjust it if
necessary {see page 18-4).
scREws5 N.m 10.5 kgl m, 4 lbl'tt)
CIRCLIP
34. Install the splash guard and tight€n the screws.
18-14
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'1.
Lower Ball Joint Replacement
Remove the knuckle (see page 18-10).
Remove the boot by prying the set ring off.
Check the boot for deterioration and damage. and
replace it if necessary.
lnstall the special tools on the ball joint, and tighten
the castle nut.
BAII JOINT BEMOVER BASE07JAF - SH2oe00
Position the special tools over the ball joint as
shown. then set the assembly in a vise. Press the
ball joint out of the knuckle.
Place the ball joint in position by hand.
Install the special tools over the ball joint as shown,
then press the balljoint in.
BAII JOINT INSTAL1IR BASE
7.
8AI.I JOINT REMOVEN/INSTALLER
BALL JOINT HOUSING SURFACE
18-15
8. Install the ball joint boot and set ring using the spe-
cial tool {see page 18-16}.
Install the knuckle in the reverse order of removal.
and pay particular attention to the following items:
. Be careful not to damage the ball joint boots
when installing the knuckle.
. Torque all mounting hardware to the specified
toroue values.
a Torque the castle nuts to the lower torque speci-
fications, then tighten them only far enough to
align the slot with the pin hole. Do not align the
castle nut by loosening.
. Install new cotter pins on the castle nuts after
IOrqurng.
Avoid twisting the sensor wires when installing
the wheel sensor.
Before installing the brake disc, clean the mating
surfaces of the front hub and the inside of the
brake disc.
Before installing the wheel. clean the mating sur-
face of the brake disc and the inside of the wheel.
Check the front wheel alignment, and adjust it if
necessary (see page 18-4).
o
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Front SuspensionFront Damper
Ball Joint Boot Replacement
1.
BALL PIT{ TAPEFEO S€CTION
B{rcY HSISECTIO BOOT |NSTSECTIONwip6 off tho gr6aso.Wipo otf th6 grors€.
Wipe the grease off the sliding surface of the ball
pin, and pack it with fresh greass. Keep grease off
the boot installation section and the taoered section
of the ball pin.
Do not allow dust, dirt, or other foreign materials to
enter the boot.
Install the boot in the groove of the boot installation
section securelv, then bleed air.
Install the upper and lower ball joint boot set rings
using the special tools as follows:
Lower ball joint: Adjust the special tool with the
adjusting bolt until the end of the tool aligns with
the groove on the boot. Slide the set ring over the
tool and into oosition.
Upper ball joint: Hold the tool over the ball joint,
then slide the set ring over the tool and into position.
EAII JOINTAD'USN G BOLTAdjust th6 depth byturning the bolt.
Remove the set ring and the boot.
Pack the interior of the boot and lip with grease. Do
not contaminate the boot installation section with
grease.
B(X)T CUPGUttrE
UPPER BAI.IJott'tr Boor:07GAG - SO407q)LOWEF BATIJOIIYI EOOTI0t97il - SA507lXl
After installing the boot, check the ball pin tapered
section for grease contamination, and wipe it if nec-gssary.
18-16
Removal
1, Remove the front wheels (see page 18-10).
2. Remove the damper pinch bolt from the top of the
damper fork.
DAMPERPINCHBOLT'10 x 1.25
SELF.LOCKING NUT12x 1.25 fifiReplace.
Remove the damper fork bolt and self-locking nut
from the bottom of the damper fork, then remove
the damper fork.
Remove the damper by removing the two nuts.
DAMPER
DAMPER FORK
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Rear Suspension
Suspension Arms Replacement
@ when the suspension arms are to be removed, plsce additional weight in lhe trunk beto.o hoisting. when
substantial weight is removed from the rear of the vehicle, the center ot grsvity m8y chango causing the vehicle to tip
forward.
Note these items during replacement:
. Replace the self-locking nuts after removal.
. Any bolts or nuts connected to rubber mounts or bushings should be tightened with the vehicle on the ground.
. Make sure the toe adjusting bolts on the compensator arm are installed in the same direction,
. After installing the suspension arm, check the rear wheel alig nment, and adjust if necessa ry (see page 18-4),
STABILIZER BARCheck for bendingor oamage.
FLANGE EOLT10 x 1.25 mm64 N.m 16.5 kgf.m,47 lbf.ft)
FLANGE BOLT10 x 1.25 mm54 N.m (5.5 kgt.m, / t40 lbf.ftt. --1 \ \A1(\
\a'v..:r
UPPER ARM BUSHINGCheck for deteriorationand damage.
il ,
FLANGE BOLT'l0 r 1.25 mm54 N.m (5.5 kgf.m,
8 mm EOLTS22 N.m {2.2 kgf.m, 16 bl.ftl
40 rbtft)
'ano oamage.
TRAILING ARMCheck for bending
stLtcoNE
-6lUPPER ARM
COMPENSATORARM BUSHING
64 N.m 16.5 kgf.m, 47 lbtftl
SELF.LOCKING NUT
BUSHING
FLANGE BOLT10 x 1.25 mm54 N.m {5.5 kgf.m, 40 lbf.ft}
FLANGE BOLTS10 x 1.25 mm39 N.m 14.0 kgf.m, 29 lbf.ft)stLtcoNE
.@iCOMPENSATORARM BUSHING
UPPER ARMCheck lor bending or damage.
FLANGE NUT10 x 1 .25 mm29 N.m {3.0 kg{.fl,22 lbf.ft}Before tightening the flange nut,position the balljoint pinin the middle of its range oftravel, with the suspension undervehicle load.
10 x 1.25 mm 29 N.m (3.0 kgl.m, 22 tbf.ft)Replace.Hold the ball ioint pin using a hex wrenct,,and tighten the self-locking nut.
STABILIZER LINK
Check tor damage.
LOWER ARM BUSHINGCheck for deterioration and damage.
. Check for bending and damage.. Check the bushing tor deterioration anddamage.
LOWEN ARM
-6ilstLrcoNE
STABILIZER 8AR
,/ FLANGE BOLT
// 10 x 1.25 mm
^/ s4 N.m 15.5 kst'm, 40 lbf ftl
BUSHING
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Front Brake Pads
Inspection and Replacement (cont'dl
9. Apply Molykote M77 grease or Daikalub 528Dgrease to both sides of the pad shims and the back
of the pads. Wipe excess grease off the shims.
Apply Molykote M77
to both sides of shims.
INOICATOR
Apply Molykote M77or 0aikalub 528Dto both sides of shim.
10.
INNER PAD
OUTER PAD
lnstall the brake pads and pad shims correctly.
Install the pad with the wear indicator on the inside.
. When reusing the pads, always reinstall thebrake pads in their original positions to prevent
loss of braking efficiency.. Contaminated brake discs or pads reduce stop-ping ability. Keep grease off the discs and pads.
19-10
'11. Push in the piston so that the caliper willfit over thepads. Make sure the piston boot is in position toprevent damaging it when pivoting the caliper
down.
CALIPER BOLT49 N.m (5.0 kgf.m, 36 lbf.ftl
13.
Pivot the caliper down into position, being careful
not to damage the pin boot. Install the caliper bolt
and tighten it,
Press the brake pedal several times to make sure
the brakes work, then test-drive.
NOTE: Engagement of the brake may require agreater pedal stroke immediately after the brakepads have been replaced as a set. Several applica-
tions of the brake pedal will restore the normalpedal stroke.
After installation, check for leaks at hose and linejoints and connections, and retighten if necessary.
14.
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Front Brake Caliper
Disassembly/Reassembly
. Never use an air hose or dry brush to clean brake assemblies.
. Use an OSHA approved vacuum cleaner to avoid breathing brake dust.
. Contaminated brake discs or pads reduce stopping ability.
. When reusing the pads, always reinstallthe brake pads in their original positions to prevent loss ol braking efficiency.
CAUTION:
. Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off imme-
diatelY with water.
NOTEI
. To prevent spills, cover the hose joints with rags or shop towels.
. Clean all pans in brake fluid and air dry; blow out all passages with compressed air.
. Before reassembling, check that all parts are free of dust and other foreign particles.
. Replace parts with new ones whenever specified to do so.
. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
. Do not reuse the drained fluid.
. Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the
life of the system.
. Coat the piston, piston seal, and caliper bore with clean brake fluid.
. ReDlace all rubber oarts with new ones whenever disassembled.
. After installing the front brake caliper do the following.- Check for leaks at hose and line joints and connections, and retighten if necessary.- Check the brake hoses for interference and twistinq.
SHIM
12 mm FLANGE BOLTS113 N.m (11.5 kgtm,83lbf.ftlINNER
ft
il1
#
\i
#
PIN B
OUTER PAO SHIM
PAD SPRING
IPIN BOOT
-Cr
SEALING WASHERSReplace.4dd*
ERAKE PADS
'f,-rre
/ tto*l "o"\
t@I
/\'
sLreo 6cnew \I N m 10.9 kStm, 6.5 lbnft)
\
6-
>PIN A
-6, {
CALIPER BOOY
CALIPER EOLTS49 N.m {5.0 kgl.m, 36lbf.ftl
PISTON AOOTReplace.
"..-a=a-...,--"sEqriPISTON
t".:jil,,.'.1!!!!9!il: Rubber grease (Use recommended grease in the caliper set)
irf"i:;;T::fl,-J'I",0 .@
--6, Silicone grease (use recommended seal grease and p,n grease in the caliper set)
INNER SHIM BWEAB INDICATOR
EANJO BOLT34 N.m {3.5 kgf m,25 lblftl
PISTON SEALReplace.
AFACKET
19-12
PAD RETAINERS
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Master Cylinder/Brake Booster
Removal/lnstallation
1, Disconnect the brake fluid level switch connectors.
2. Remove the reservoir cap from the master cylinder.
3. Remove the brake fluid from the master cvlinder
reservoir with a syringe.
4. Disconnect the brake lines from the master cylinder.
To prevent spills, cover the line joints with rags or
shop towels.
5. Remove the master cylinder mounting nuts and
wasners.
6. Remove the master cylinder from the brake booster.
CAUTION: Be careful not to bend or damage the
brake lines when removing the master cylinder.
Do not spill brake fluid on the vehicle; it may dam.
age the paint; it brake fluid does cont.ct the paint,
wash it oft immediately with water.
7. Disconnect the vacuum hose from the brake booster.
8. Remove the cotter pin and clevis pin from the clevis.
Do not disconnect the clevis by removing it from
the operating rod of the brake booster. lf the clevis
is loosened, adjust the pushrod length before
installing the brake booster (see page 19-15).
To Front Caliper (Without ABS)
\\
15 N.m {1.5 kgtm, vAcuuM HosE
r r rbf.ft) |
/ | BRAKE FLUTD LEvEL
/l /
swrrcHcoNNEcroRs
/ I I I COTTER PIN
I I / neotace
l,/-- ro Rear wheet cylinders / | I
h ./-''' /. I I IYli //*s (.S
I /r:
9. Remove the four booster mounting nuts.'10. Pull the brake booster forward until the clevis is
clear of the bulkhead.
11. Remove the brake booster from the enqine com-
panment.
12. Install the brake booster and master cylinder in the
reverse order of removal, and note these items:
. When connecting the brake lines, make sure that
there is no interference between the brake lines
and other parts.
. Be careful not to bend or damage the brake lines
when installing the master cylinder.
. lf replacing the master cylinder or brake booster,
check and adjust the pushrod clearance before
installing the master cylinder (see page 19-14).
Fill the master cylinder reservoir, and bleed the
brake system (see page 19-7).
After installation, check the brake pedal height and
brake pedal free play (see page 19-5), and adjust if
necessary.
13 N.m 11.3 kg{.m,I rbf.ft)
13.
14.
To Master Cylinder(Without ABS)To Modulator Unit(with ABs)@-\
\
^ To Front Caliper
9i\.
-#qCLEVIS PIN
):-,/
PROPORTIONING CONTROL VALVE
MASTER CYLINDER
15 N.m (1.5 kgf.m, 11 lbl.ftl
BRAXE BOOSTER
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